When Poor Habits Become the Norm
Opening Scene
Imagine an intricate and lengthy production line, where every minute of inactivity costs thousands of dollars. The constant buzz of motors and conveyors conceals a profound tension: production goals are approaching, supervisors are vigilant, and the pressure remains unyielding.
In a constrained environment with a limited maintenance budget and sparse spare parts, your inexperienced and stretched-thin team constantly reacts to urgent breakdowns, prioritizing speed over thoroughness. Shortcuts become necessary for survival, leading to misaligned work and temporary fixes. While immediate repairs may succeed, small defects accumulate, resulting in entrenched bad habits and hidden failures. Eventually, a critical breakdown occurs, revealing the underlying issues, marking the start of a necessary investigation.
Understanding Failure
Every failure has a signature; Bearings show internal and external evidence. Internal evidence includes scoring, pitting, or spalling on the raceways and rollers, which tell a story of stress and neglect. Externally, you might notice abnormal vibration or noise, subtle whispers of distress that often go unheard in the cacophony of the production line.
Every failure has a signature; Bearings show internal and external evidence. Internal evidence includes scoring, pitting, or spalling on the raceways and rollers, which tell a story of stress and neglect. Externally, you might notice abnormal vibration or noise, subtle whispers of distress that often go unheard in the cacophony of the production line.
Crime Scene
In our investigation, we examine these signatures like detectives at a crime scene, piecing together the narrative of wear and tear. Each scratch and scar is a clue, a chapter in the machine’s life that speaks volumes about its treatment and care or lack thereof.
During our investigation, we observed that the machine is not secured to the ground (unbolted). There is a slight micro-movement occurring as the production is being conveyed. The bearing exhibits typical signs of creep, including discoloration around the seal and bearing interface, as well as the presence of sludge.
Component: Deep Groove Ball Bearing
Industry: General Manufacturing
Observed Condition: Pitting, uneven wear, outer race scoring, discoloration, sludge.
Machine Mounting: Free-floating, unbolted
The Failure Modes (Aggressive Agents)
- Micro-vibrations: Unbolted machine
- Misalignment: Eyeballed installation
- Impact Loading: Machine movement during startup/shutdown
- Raceway Fretting: Accelerated by looseness
- Lubrication Stress: Micro-movement and heat
- Poor Sanitation Practices: Water ingress, aggressive chemicals, debris
Individually, these symptoms seem minor. Together, the produce cumulative, compounding damage, until the machine crosses the P-F curve and operators are left in shock when it “failed without warning.”
The Fingerprints (Clues of the Crime)
- Bearing has polished wear marks on the raceway.
- Pitted surfaces showing repeated micro-movement.
- Reddish discoloration – early fretting.
- Uneven wear indicating dynamic misalignment
- Cage marks showing load fluctuations.
Degrades
until
failure
Interview
During our discussions with the operators and technicians in the area, we discovered that the bearings here have a persistent history of early failure. The average meantime to failure is approximately three to six months. One technician mentioned that they lack the tools necessary to measure alignment during installation, as they are responsible for purchasing their own equipment. Consequently, they rely on visual estimation. This reliance on guesswork has unfortunately become the norm, leading to a cycle of repeated mistakes and costly downtime. The operators expressed frustration, not only with the lack of proper tools but also with the insufficient training on how to recognize early warning signs of machine distress.
One veteran technician lamented, “We’re set up to fail before we even start.” This sentiment underscores the critical need for systemic change.
Technician’s Statements
“We’re run machines unbolted for years.”
“I’ve seen worse and they still ran fine.”
This is classic EXPERIENCE BIAS.
When ineffective practices do not lead to instant failure, they often become justified, normalized, and ultimately defended. The issue? Machine health does not COMPROMISE with our BIASES.
The Culprit (Who Did It):
- Lack of proper anchoring: Foundation instability
- Poor Installation practices: Misalignment
- Absence of torque specification: Improper preload
- Preventative maintenance gap: No vibration trending
- Cultural acceptance of deviations: Normalized defects
Forensic Assessment
The inquiry extends beyond merely identifying what went awry; it delves into why it was permitted to occur.
- Did the pressure to achieve targets prompt a quick fix instead of a thorough repair?
- Was there insufficient training that left team members oblivious to the subtle indicators of looming failure?
- Is there an over-reliance on technicians to acquire and maintain their own equipment?
- Or was it merely the normalization of shortcuts that became the accepted practice?
The Real Culprit: Normalization of Deviance
| This case isn’t about bearing failure. It’s about the mindset. When organizations accept: “We’ve always doesn’t it this way.” “It’s still running, so it’s fine.” “We don’t need precision for this machine.” | They inadvertently allow defects to mature into failures. The enemy is not ignorant, its complacency cloaked as experience. |
The Fix is Simple
- Bolt and anchor assemblies per OEM
- Laser alignment, not eyeballing
- Torque tools with documented values
- Condition monitoring baseline
- Technician training that closes experience gaps
- Program to improve sanitation practices
By investing in the right tools and thorough training, the team can transition from a reactive firefighting approach to a proactive maintenance strategy. This change not only enhances machine reliability but also elevates team morale, as members develop confidence and competence in their responsibilities.
As we move forward, it is crucial to cultivate an environment that prioritizes open communication and continuous learning. By addressing these foundational aspects, the production line can transform into a model of efficiency and resilience, where every team member feels appreciated and empowered to thrive.
Grasping these subtleties is essential. It goes beyond merely repairing machines; it involves shifting mindsets, breaking free from complacency, and nurturing a culture of proactive maintenance. In doing so, we not only prevent future breakdowns but also inspire the team to take pride in their work, ensuring the line operates smoothly day in and day out.
